Intelligent configuration of a user interface of a machinery health monitoring system

ABSTRACT

A machinery health monitoring module processes machine vibration data based on vibration signals and provides the machine vibration data to a distributed control system. A distributed control system operator computer executes a software user interface that filters relevant configuration parameters based on a selected machine measurement type so that only those parameters that are applicable to the selected measurement type appear on the user interface screen. Further, configuration parameters for individual measurement values within the measurement type are made available only when a particular measurement value is selected for acquisition. This greatly simplifies the information that is displayed on the configuration user interface.

RELATED APPLICATIONS

This application claims priority to provisional patent application Ser.No. 62/029,606, filed Jul. 28, 2014, titled “Methods and Apparatus forIntegral Vibration Input and Output Card with Process Control System.”

FIELD

This invention relates to the field of machine control and machinecondition monitoring. More particularly, this invention relates to asystem for automatically configuring a user interface screen in adistributed control system to simplify the presentation of machinecondition monitoring configuration options based on specific types ofmeasurements to be made on a machine.

BACKGROUND

In prior machinery health monitoring and machine protection systems,unique data acquisition hardware electronics were required for differentmeasurement types, such as Relative Shaft Vibration, Case Vibration,Axial Thrust/Differential Expansion, Case Expansion, Eccentricity, andTachometer measurements. More recently, hardware circuitry has beendeveloped that can be configured to perform multiple measurement typesusing common acquisition hardware electronics. However, due to softwarelimitations or programming shortcuts, the software user interface forconfiguring machinery health monitoring/protection systems and processcontrol systems has continued to present configuration parameters thatare not applicable to a specific measurement type. This unnecessarilycomplicates the process of configuring such systems for specificmeasurement types.

For example, as shown in FIG. 4, a known configuration user interfacefor a process control I/O card provides configuration tabs for bothanalog and digital channels, although the associated I/O module can beonly an analog module or a digital module—not both.

In another example depicted in FIG. 5, machinery protection measurement“Keyphasor” configurations are displayed for an Acceleration measurement(and grayed out), although these configuration options do not apply tothe selected measurement type. This results in an unnecessarilycomplicated and crowded configuration display screen.

In yet another current example depicted in FIG. 6, the nX machineryprotection measurement configuration parameters are displayed (andgrayed out), although the measurement value checkboxes have not beenselected. Again, this results in an unnecessarily complicatedconfiguration display screen.

Therefore, what is needed is an intelligent user interface thatautomatically presents to the user only those configuration options thatare needed for specific measurements that are to be made using specificsensor types.

SUMMARY

Various embodiments of the invention provide a software user interfacethat filters relevant configuration parameters based on a selectedmachine measurement type so that only those parameters that areapplicable to the selected measurement type appear on the user interfacescreen. Further, configuration parameters for individual measurementvalues within the measurement type are made available only when aparticular measurement value is selected for acquisition. This greatlysimplifies the information that is displayed on the configuration userinterface.

Embodiments of the present invention provide a machinery healthmonitoring module that processes machine vibration data based onvibration signals and provides the machine vibration data to adistributed control system. The machinery health monitoring modulepreferably includes signal conditioning circuitry, processing circuitryand logic generator circuitry. The signal conditioning circuitry has aninterface for receiving analog sensor signals from sensors attached to amachine, amplification and filter circuitry for conditioning the analogsensor signals, and analog-to-digital conversion circuitry forconverting the analog sensor signals into digital sensor signals. Theprocessing circuitry includes multiple parallel digital signalprocessing channels, each of which is operable to process acorresponding one of the digital sensor signals to generate multipledifferent types of measurement data per channel. The logic generatorcircuitry is operable to receive a first type of measurement data fromthe processing circuitry and to determine that a machine operating statehas changed as indicated by the first type of measurement data. Thelogic generator circuitry is also operable to configure the processingcircuitry to generate a second type of measurement data based on thechange in machine operating state. The logic generator circuitry formatsthe first and second types of measurement data according to aninput/output data protocol that is native to the distributed controlsystem.

In some embodiments, the analog sensor signals include at least oneanalog tachometer signal, the analog-to-digital conversion circuitryconverts analog tachometer signal to a digital tachometer signal, theprocessing circuitry processes the digital tachometer signal to generatemachine speed data, and the logic generator circuitry determines thatthe machine operating state has changed as indicated by a change in themachine speed data.

In some embodiments, the logic generator circuitry determines that themachine operating state has changed from a steady-state speed conditionto a coast-down state based on the machine speed data, and it configuresthe processing circuitry to generate the second type of measurement datacomprising a transient vibration waveform measured while the machine isin the coast-down state.

In some embodiments, the logic generator circuitry determines that themachine operating state has changed based on the machine speed dataindicating a drop in machine speed from above a predetermined speedthreshold to below the predetermined speed threshold, and it configuresthe processing circuitry to generate the second type of measurement datawhile the machine operating state is below the predetermined speedthreshold and to generate the first type of measurement data while themachine operating state is above the predetermined speed threshold.

In some embodiments, the first type of measurement data is collectedover a first frequency range and the second type of measurement data iscollected over a second frequency range that is different from the firstfrequency range.

In some embodiments, at least one of the parallel digital signalprocessing channels of the processing circuitry generates themeasurement data in the form of a time waveform of the digitaltachometer signal.

In some embodiments, the logic generator circuitry is in electricalcommunication with an input/output bus of the distributed control systemthrough which the logic generator circuitry receives discrete inputvalues indicative of the machine operating state that are generated byother machine measurement modules connected to the input/output bus. Thelogic generator circuitry determines that the machine operating statehas changed based on a change in one or more of the discrete inputvalues, and it adjusts alarm levels or generates the second type ofmeasurement data based on the change in one or more of the discreteinput values.

In some embodiments, the sensor signals include a machine vibrationsignal, and the processing circuitry includes a peak value detectionchannel that receives the machine vibration signal, samples the machinevibration signal during predetermined sample time periods, detects peakamplitude values of the machine vibration signal during the sample timeperiods, and produces a time series of the peak amplitude values. Inthese embodiments, the first or second type of measurement datacomprises the time series of the peak amplitude values.

In another aspect, embodiments of the invention are directed to adistributed control system that includes an input/output bus, machineryhealth monitoring module, a distributed control system controller, and adistributed control system operator computer. Data are transferredthrough the input/output bus according to a data communication protocolthat is native to the distributed control system. The machinery healthmonitoring module preferably includes signal conditioning circuitry,processing circuitry and logic generator circuitry. The signalconditioning circuitry has an interface that receives analog vibrationsignals from vibration sensors attached to a machine, amplification andfilter circuitry for conditioning the analog vibration signals, andanalog-to-digital conversion circuitry for converting the analogvibration signals into digital vibration signals. The processingcircuitry includes multiple parallel digital processing channels, eachof which processes a corresponding one of the digital vibration signalsto generate multiple scalar vibration values per channel. The logicgenerator circuitry receives the scalar vibration values and formats thescalar vibration values according to an input/output communicationprotocol that is native to the distributed control system. Thedistributed control system controller includes interface circuitryhaving one or more fast-scan registers. The interface circuitry isoperable to scan the input/output bus at a predetermined rate to receiveone or more of the scalar vibration values into the fast-scan registers.The distributed control system operator computer executes user interfacesoftware to:

-   -   generate a first graphical user interface screen for display on        a user interface device, which includes a measurement type        selection field and does not include sensor configuration option        fields,    -   receive a measurement type selection entered by a user in the        measurement type selection field,    -   based on the measurement type selection, generate a second        graphical user interface screen for display on the user        interface device, which includes one or more sensor        configuration option fields that were not included in the first        graphical user interface screen, where the sensor configuration        option fields are specific to a sensor type to be used in making        a measurement indicated by the measurement type selection,    -   receive sensor configuration selections entered by the user in        the sensor configuration option fields, and    -   generate configuration data for configuring the machinery health        monitoring module based on the measurement type selection and        the sensor configuration selections.

In some embodiments, the distributed control system operator computerexecutes the user interface software to automatically assign one or moreof the scalar vibration values to be read into the one or more fast scanregisters, wherein the assignment is based at least in part on themeasurement type selection.

In some embodiments, the distributed control system operator computerexecutes user interface software to:

-   -   generate a graphical user interface screen that includes a        machinery trip time delay input field that is initially preset        to a default trip time delay value as prescribed by an industry        standard, such as the API 670 Standard,    -   generate the graphical user interface screen to include one or        more input option fields for the machinery trip time delay, in        which trip time delay values other than the default trip time        delay value may be entered by a user,    -   receive a trip time delay selection entered by a user in the        machinery trip time delay input field, and    -   generate configuration data for configuring the control logic        routine based at least in part on the trip time delay selection.

In some embodiments, the distributed control system operator computerexecute the user interface software to:

-   -   generate configuration data for the control logic routine to        initially implement a machinery protection bypass as prescribed        by the industry standard for multiple sensor inputs        corresponding to the multiple sensors,    -   generate the graphical user interface screen to include one or        more input option fields in which the user may choose to disable        the machinery protection bypass for one or more of the sensor        inputs,    -   receive a machinery protection bypass selection entered by the        user in the one or more input option fields, and    -   generate configuration data for the control logic routine based        at least in part on the machinery protection bypass selection.

In some embodiments, the distributed control system operator computerexecutes the user interface software to:

-   -   generate configuration data for the control logic routine to        initially implement a trip multiply as prescribed by the        industry standard for all sensor inputs corresponding to the        multiple sensors,    -   generate the graphical user interface screen to include one or        more input value fields for the trip multiply,    -   generate the graphical user interface screen to include one or        more input option fields in which the user may choose to disable        the trip multiply for one or more of the sensor inputs,    -   receive trip multiply selections entered by the user in the one        or more input option fields, and generate configuration data for        the control logic routine based at least in part on the trip        multiply selections.

In some embodiments, the distributed control system operator computerexecutes the user interface software to:

-   -   generate configuration data for the control logic routine to        initially implement voting logic that allows or disallows a        failed sensor to contribute to a vote to trip as prescribed by        the industry standard,    -   generate the graphical user interface screen to include one or        more input option fields in which the user may choose to allow        or disallow a failed sensor to contribute to a vote to trip,    -   receive failed sensor voting option selections entered by the        user in the one or more input option fields, and    -   generate configuration data for the control logic routine based        at least in part on the failed sensor voting option selection.

In some embodiments, the distributed control system operator computerexecutes the user interface software to:

-   -   generate configuration data for the control logic routine to        initially implement alarm limits or alert limits as prescribed        by the industry standard,    -   generate the graphical user interface screen to include one or        more input value fields for the alarm limits or alert limits,    -   receive alarm limit or alert limit selections entered by the        user in the one or more input value fields, and generate        configuration data for the control logic routine based at least        in part on the alarm limit or alert limit selections.

BRIEF DESCRIPTION OF THE DRAWINGS

Other embodiments of the invention will become apparent by reference tothe detailed description in conjunction with the figures, whereinelements are not to scale so as to more clearly show the details,wherein like reference numbers indicate like elements throughout theseveral views, and wherein:

FIG. 1 depicts a machinery health monitoring (MHM) module according toan embodiment of the invention;

FIG. 2 depicts field digital FPGA signal processing circuitry accordingto an embodiment of the invention;

FIG. 3 depicts an example of control logic executed by a DCS controlleraccording to an embodiment of the invention;

FIGS. 4, 5 and 6 depict examples of prior art machinery protectionsoftware user interface screens;

FIGS. 7-11 depict examples of measurement channel configurationinterface screens according to embodiments of the invention; and

FIGS. 12-14 depict process flow diagrams for methods for configuringmeasurement channels according to embodiments of the invention.

DETAILED DESCRIPTION

Embodiments of the present invention provide a vibration dataacquisition and analysis module that interfaces directly to adistributed control system I/O backplane to allow direct acquisition ofvibration data by the DCS for purposes of machinery protection andpredictive machinery health analysis. As the term is used herein, a“distributed control system (DCS)” is a type of automated control systemused in a process or plant in which control elements are distributedthroughout a machine or multiple machines to provide operationalinstructions to different parts of the machine(s). As the term is usedherein, “protection” refers to using data collected from one or moresensors (vibration, temperature, pressure, etc.) to shut down a machinein situations in which severe and costly damage may occur if the machineis allowed to continue running “Prediction” on the other hand refers tousing data collected from one or more vibration sensors, perhaps incombination with data from other types of sensors, to observe trends inmachine performance and predict how much longer a machine can operatebefore it should be taken offline for maintenance or replacement.

FIG. 1 depicts a machinery health monitoring module (MHM) 10 thatdirectly interfaces with a DCS 11. In the preferred embodiment, themodule 10 includes a field analog signal conditioning and sensor powercard 12 that receives and conditions sensor signals, a field digitalFPGA signal processing card 14 that processes the sensor signals, and aDCS logic generator card (LGC) 16 that provides an interface to a DCSI/O bus 18. The field card 12 can preferably accept input from at leasteight measurement sensors 20 through a field signal interface connector22. In a preferred embodiment, at least two of the sensor input channelsmay be configured as tachometer channels.

Preferably, galvanic electrical isolation is provided between the analogfield card 12 and the digital field card 14. This electrical isolationprevents unintentional current flow, such as due to ground loops,between the mounting locations of the sensors 20 and the DCS 11.

Sensor power 24 and signal conditioning circuits 26 can support a widerange of sensors 20, including piezo accelerometers, piezo ICP velocity,piezo dynamic pressure, electro-dynamic velocity, eddy currentdisplacement, AC vibration, and DC displacement, with 4-20 mA inputcurrent. Tachometer sensors that are supported include eddy currentdisplacement sensors, passive electro-magnetic sensors, Hall Effecttachometer sensors, N pulse/rev shaft encoders, and TTL pulse sensors.Many additional sensor types are supported over the frequency range ofDC to 20 KHz as long as they fall within the following exemplary voltageinput ranges: 0 to +24V, −24V to +24V, −12V to +12V, and 0 to −24V. Inthe preferred embodiment, up to eight sensor power circuits 24 can beindividually programmed for a constant current of between 0 and 20 mA,which may also be used as lift current for an electro-dynamic (passive)velocity sensor. The input voltage ranges listed above are alsoindividually programmable on each sensor channel. This permits any mixof sensor power and input range configuration between the channels,thereby enabling a mix of supported sensors.

With timing provided by a clock 26, an 8-channel analog-to-digitalconverter (ADC) 28 converts the eight analog signals into a singleserial data stream comprising eight simultaneously sampled interleavedchannels of data. In some preferred embodiments, two tachometertriggering circuits 30 convert the two analog tachometer signals intotachometer pulses.

On the field card 14 is an 8-channel field programmable gate array(FPGA) 36 for processing the vibration data. The FPGA 36 receives the8-channel digital waveform data, including possibly 2-channels oftachometer data, and processes the raw data in parallel to generatescalar overall vibration parameters and waveforms. The processedwaveforms may include low-pass filtered, PeakVue™, order tracking,high-pass filtered (DC blocked), and selectable single-integrated(velocity), double-integrated (displacement), or non-integrated(acceleration) waveforms. These waveforms may also be generated on thetwo data channels dedicated to tachometer data. Prediction data channelsalso preferably include an up-sampling data block to provide higherresolution data for Time Synchronous Averaging (TSA) order trackingapplications.

The vibration card configuration circuit 32 of the analog field card 12preferably includes of a set of serial-to-parallel latch registers thataccept a serial data stream of configuration data from the applicationfirmware of the LGC 16. This data is loaded into a parallel-to-serialshift register in the interface of the FPGA 36. The FPGA 36 then handlesshifting the serial data to the control latches using a synchronous SPIformat.

During operation of the preferred embodiment, the MHM module 10 appearsto the DCS controller 19 as a multichannel analog input card havingscalar outputs similar to those of a standard DCS input module 21, suchas may be outputting measured temperature, pressure, or valve positionvalues. As discussed in more detail hereinafter, vibration signals areconverted to scalar values by the module 10 and presented to the DCScontroller 19 via the backplane of the DCS. One example of a DCScontroller 19 is the Ovation™ controller manufactured by Emerson ProcessManagement (a division of Emerson Electric Co.). In this DCSarchitecture, up to sixteen scalar values are presented from each I/Omodule as high speed scan values to the DCS controller 19. In a highspeed scan, the DCS controller 19 can read these sixteen scalar valuesat up to a 10 mS rate.

Time waveform block data (and additional scalar values) may betransferred to the DCS controller 19 via the DCS I/O bus 18 using ablock data transfer method, such as Remote Desktop Protocol (RDP), at arate that is lower than the scan rate of the sixteen high speed scalarvalues.

As the scalar values generated by the machinery health monitoring module10 are read by the DCS controller 19, they are processed by softwarerunning in the DCS controller 19 in the same manner as any other DCSdata. One primary function of the DCS controller 19 is to compare thescalar values with alarm limits. If the limits are exceeded, alarms aregenerated. Logic within the DCS controller 19 may also determine whetherany actions should be taken based on alarm conditions, such as closing arelay. Operations including alarm relay logic, voting, and time delaysare also performed in software by the DCS controller 19. Preferably, DCScontrol outputs, such as relay outputs and 4-20 mA proportional outputs,are driven by standard output modules 23 of the DCS. Bulk predictiondata is formatted in the LGC host processor 48 and is transmitted via anEthernet port 52 a to a machine health management (MHM) analysiscomputer 54 for detailed analysis and display. Bulk protection data isalso formatted in the LGC host processor 48, but is transmitted via aseparate Ethernet port 52 b to the DCS operator computer 60.

In preferred embodiments, a DCS operator computer 60 includes aninterface for displaying vibration parameters and other machineoperational data (pressures, temperatures, speeds, alarm conditions,etc.) that are output from the DCS controller 19.

A functional block diagram of a single channel of the field digital FPGA36 is depicted in FIG. 2. A preferred embodiment includes sevenadditional channels having the same layout as the one channel depictedin FIG. 2. As described in more detail hereinafter, the channel digitalwaveform data may be routed through a variety of digital filters andintegration stages before being converted to vibration overall values orpackaged as “bulk” time waveforms for further analysis by softwarerunning on the LGC card 16 or for transmission to DCS software or MHMsoftware.

As shown in FIG. 2, an ADC interface 70 receives the eight channels ofcontinuous, simultaneously sampled data from the ADC 28 of the fieldanalog card 12 through the connector 34 (shown in FIG. 1). The data ispreferably in the form of a multiplexed synchronous serial data streamin Serial Peripheral Interface (SPI) format. The ADC interface 70de-multiplexes the data stream into eight separate channel data streams.

Although all eight channels could be used for vibration signalprocessing, in a preferred embodiment two of the eight channels can beused for tachometer measurement processing. Each tachometer measurementchannel preferably includes:

-   -   a one-shot 110, which is a programmable trigger “blanking”        function that provides noise rejection for tachometer pulse        trains having excessive jitter or noise;    -   a divide-by-N 111, which is a programmable pulse divider that        divides pulse rates of tachometer signals produced by gears or        code wheels;    -   a reverse rotation detector 112 that determines the direction of        shaft rotation by comparing the phase of two tachometer pulse        signals;    -   an RPM indicator 115 that calculates the RPM of the tachometer        pulse stream as a scalar overall value.    -   a zero-speed detector 113 that provides a “zero speed”        indication when the tachometer has been inactive for a        programmable interval, such as 0.1 s, 1 s, 10 s, or 100 s; and    -   a detector 114 that provides an “over range” indication when the        tachometer exceeds a fixed 2 KHz or 62 KHz threshold. In        alternative embodiments, this threshold may be programmable.

With continued reference to FIG. 2, each of the eight independentparallel channels of signal processing in the FPGA 36 preferablyincludes the following components:

-   -   a high pass filter 72 for DC blocking, which can preferably be        set to 0.01 Hz, 0.1 Hz, 1 Hz, or 10 Hz, and which may be        selected or bypassed for the integrators described below based        on the position of a switch 74;    -   two stages of digital waveform integration, including a first        integrator 76 and a second integrator 78, which provide for data        unit conversion from acceleration to velocity, acceleration to        displacement, or velocity to displacement;    -   a digital tracking band pass filter 82 having a band pass center        frequency that is set by the tachometer frequency or multiples        of the tachometer frequency, and that receives as input either        the “normal” data stream (no integration), the single        integration data stream, or the double integration data stream        based on the position of a switch 80, as described in more        detail below; and    -   scalar overall measurement calculation blocks 88-100 that        determine several different waveform scalar overall values as        described below.

In the preferred embodiment, the purpose of the digital tracking bandpass filter 82 is to provide a narrow (high Q) band pass response with acenter frequency determined by the RPM of a selected tachometer input.The center frequency may also be a selected integer multiple of thetachometer RPM. When a waveform passes through this filter, onlyvibration components corresponding to multiples of the turning speed ofthe monitored machine will remain. When the RMS, peak, or peak-to-peakscalar value of the resultant waveform is calculated by thecorresponding FPGA calculation block (88, 90 or 92), the result is sameas a value that would be returned by an “nX peak” calculation performedin the application firmware of the LGC 16. Because this scalarcalculation is performed as a continuous process in the FPGA 36 ratherthan as a calculation done in firmware, it is better suited to be a“shutdown parameter” as compared to a corresponding value produced at alower rate in firmware. One application of this measurement is inmonitoring aero-derivative turbines, which generally require a trackingfilter function for monitoring.

For several of the scalar overall values, the individual data type fromwhich the values are calculated may be selected from the normal datastream, the single-integrated data stream, the double-integrated datastream, the high-pass filtered (DC blocked) data stream, or the trackingfilter data stream based on the positions of the switches 84 a-84 d.Also, several of the scalar overall channels have anindividually-programmable low-pass filter 88 a-88 d. In the preferredembodiment, these scalar overall values are generated independently ofand in parallel to the time waveforms that are used for prediction orprotection. The scalar overall measurement calculation blocks preferablyinclude:

-   -   an RMS block 88 that determine the RMS value of the time        waveform, where the RMS integration time may preferably be set        to 0.01 s, 0.1 s, 1 s, or 10 s;    -   a peak block 90 that determines the greater of the positive or        negative waveform peak value relative to the average value of        the waveform, which is preferably measured over a period        determined by either the tachometer period or a programmable        time delay;    -   a peak-peak block 92 that determines the waveform peak-to-peak        value over a period determined by either the tachometer period        or a programmable time delay;    -   an absolute +/− peak block 94 that determines the value of the        most positive signal waveform excursion and the value of the        most negative signal waveform excursion relative to the zero        point of the measurement range, which is preferably measured        over a period determined by either the tachometer period or a        programmable time delay;    -   a DC block 96 that determines the DC value of the time waveform,        which has a measurement range preferably set to 0.01 Hz, 0.1 Hz,        1 Hz, or 10 Hz; and    -   a PeakVue™ block 100 that determines a scalar value representing        the peak value of the filtered and full-wave-rectified PeakVue™        waveform as described in U.S. Pat. No. 5,895,857 to Robinson et        al. (incorporated herein by reference), which is preferably        measured over a period determined by either the tachometer        period or a programmable time delay. Full wave rectification and        peak hold functions are implemented in the functional block 98.        The PeakVue™ waveform from the block 98 is also made available        as a selectable input to the prediction time waveform and        protection time waveform processing described herein.

The prediction time waveform processing section 116 of the FPGA 36provides a continuous, filtered time waveform for use by any predictionmonitoring functions. An independent lowpass filter/decimator 104 a isprovided so that the prediction time waveform may be a differentbandwidth than the protection time waveform. A waveform up-samplingblock 106 provides data rate multiplication for analysis types such asTime Synchronous Averaging (TSA) and Order Tracking Input to theprediction time waveform processing section 116 may be selected from thenormal data stream, the single-integrated data stream, thedouble-integrated data stream, the high-pass filtered (DC blocked) datastream, or the PeakVue™ data stream based on the positions of the switch102 a.

The protection time waveform section 118 of the FPGA 36 provides acontinuous, filtered time waveform for use by protection monitoringfunctions. An independent low pass filter/decimator 104 b is provided sothat the protection time waveform may be a different bandwidth than theprediction time waveform. Input to the protection time waveformprocessing section 118 may be selected from the normal data stream, thesingle-integrated data stream, the double-integrated data stream, thehigh-pass filtered (DC blocked) data stream, or the PeakVue™ data streambased on the positions of the switch 102 b.

Preferred embodiments provide for transient data collection, whereincontinuous, parallel time waveforms from each signal processing channelmay be collected for transmission to external data storage. Transientwaveforms are preferably fixed in bandwidth and are collected from theprotection time waveform data stream.

As shown in FIG. 1, the scalar overall values, as well as the digitallyfiltered time waveforms, pass through the LGC interface 38 to the LGClogic board 16 for further processing and transportation to the DCScontroller 19 via the DCS I/O backplane 18 or to external softwareapplications running on the MHM data analysis computer 54 via theEthernet port 52.

FIG. 3 depicts an example of a control logic routine (also referred toherein as a control sheet) that is performed by the DCS controller 19.In preferred embodiments, a control sheet is scheduled to execute at apredetermined rate, such as 1 sec, 0.1 sec, or 0.01 sec, by the DCSsoftware running in the controller 19. As the control sheet thatcontrols the vibration process is executed, scalar overall vibrationvalues are scanned from the DCS I/O bus 18 and output values aregenerated at the execution rate of the control sheet.

Logic functions performed by the control sheets preferably include:

-   -   Voting logic, such as logic to determine that an alert condition        exists if 2 out of 2 scalar values are over threshold, or 2 out        of 3 are over threshold.    -   Combining vibration data with other DCS process parameter data        (such as pressure and temperature).    -   Trip multiply, which is a temporary condition determined by        current machine state or by manual input that increases an alarm        level. Trip multiply is typically used during the startup of a        rotational machine, such as a turbine. As the turbine speeds up,        it normally passes through at least one mechanical resonance        frequency. Since higher than normal vibration conditions are        measured during this resonance, “trip multiply” is used to        temporarily raise some or all of the alarm levels to avoid a        false alarm trip. The trip multiply input may be set manually        with operator input, or automatically based on RPM or some other        “machine state” input.    -   Trip bypass, which is typically a manual input to suppress        operation of the output logic to disable trip functions, such as        during machine startup. Trip bypass is a function that        suppresses either all generated vibration alarms, or any outputs        that would be used as a trip control, or both. The trip bypass        input may be set manually with operator input, or automatically        based on some “machine state” input.        Time delay, which is a delay that is normally programmed to        ensure that trip conditions have persisted for a specified time        before allowing a machine trip to occur. Trip time delays are        normally set to between 1 and 3 seconds as recommended by the        API 670 Standard. The purpose of this delay is to reject false        alarms caused by mechanical or electrical spikes or glitches.

Intelligent Configuration of User Interface

As discussed above, the DCS operator computer 60 provides an interfacefor displaying vibration parameters and other machine operational dataoutput from the DCS controller 19. In a preferred embodiment, the DCSoperator computer 60 executes user interface (UI) software that, amongother things, creates a configuration file for configuring themeasurement channels of the MHM module 10. This configuration file ispreferably received by the LGC Host Processor 48, which uses it toconfigure many of the other components of the MHM module 10.

Examples of UI screens for configuring the measurement channels aredepicted in FIGS. 7-11. FIGS. 12-14 depict process flow diagrams forembodiments of methods for configuring measurement channels.

FIG. 7 depicts an initial channel configuration screen 200 that providesfor configuring eight vibration measurement channels 202 and twoexternal tachometer channels 204 (step 300 in FIG. 12). In this initialconfiguration screen 200, no measurement type has been selected forChannel 1 on the input configuration tab, and no measurement specificconfiguration input fields are displayed. FIG. 8 depicts the channelconfiguration screen 200 wherein a Relative Shaft Vibration measurementtype has been selected in the input field 206 for Channel 1 in the inputconfiguration tab (step 302). Upon selection of the Relative ShaftVibration measurement type, the screen 200 automatically updates todisplay only configuration input fields 208 for the Channel 1 inputconfiguration tab that are associated with that particular measurementtype (step 304). For example, input fields for the following parametersare exposed to allow for selection of the appropriate configurationvalues: Lower CutOff Frequency, Converter Model, Sensor Working RangeStart, Sensor Working Range End, Sensor Model and Sensor Sensitivity.

FIG. 9 depicts the channel configuration screen 200 wherein a Tachometermeasurement type has been selected in the input field 206 for Channel 7in the input configuration tab (step 302). Upon selection of theTachometer measurement type, the screen 200 automatically updates todisplay only configuration parameter input fields 208 in the Channel 7input configuration tab that are associated with tachometer measurements(step 304). FIG. 10 depicts an example wherein the parameters tab of thechannel configuration screen 200 has been selected for a tachometermeasurement type (step 306). At this point, no tachometer measurementvalues have been selected in the input fields 210, and no configurationparameters are displayed. FIG. 11 depicts an example wherein severaltachometer measurements have been selected (RPM, Zero Speed Detection,Reverse Rotation Detection, Rotor Acceleration, DC Gap Voltage, and OnDemand Tach Waveform Data) (step 308). Based on selection of thesemeasurements, input fields 210 for several relevant configurationparameters are automatically exposed to allow for configuration of theselected measurements (step 310).

As discussed previously, the MHM module 10 converts vibration signals toscalar values and makes those scalar values available to the DCScontroller 19 via the DCS I/O bus 18 (FIG. 1). In the typical DCSarchitecture, sixteen scalar values are made available as high-speedscan values that the DCS controller 19 reads at a predetermined rate,such as about every 10 mS. These values are read into “fast scan”registers in the DCS controller 19.

Based on the availability of sixteen high-speed scan values on the DCSI/O bus 18, two fast scan registers are assigned to each of the eightchannels of the MHM module 10. As discussed above, the parallelmeasurement processing channels of the MHM module 10 are actuallycapable of producing more than two types of measurement values for eachsensor input. In a preferred embodiment, software executed in the DCSlogic generator card 16 automatically selects two of the multiplemeasurement values for each measurement channel to assign to the fastscan registers based on the type of measurement selected (step 312 inFIG. 12). For example, if the type of measurement selected is RelativeShaft Vibration, the two selected measurement values assigned to thefast scan registers may be Overall Peak to Peak and DC Gap Voltage.

In some preferred embodiments, firmware executed in the DCS logicgenerator card 16 monitors machine state (step 316 in FIG. 13), such asbased on machine speed measurements (step 314), and initiates uniquemachinery health measurements or adjusts certain alarm levelscorresponding to the unique machine state (step 318). For example, ifthe machine RPM output by the RPM indicator 115 shows that the machinestate has changed from a steady-state speed condition to atrip/coast-down state, the software initiates the recording of a gaplesstransient waveform of vibration data during the coast-down period. Thiswaveform data may come from the prediction time waveform processingsection 116 of the FPGA 36. As another example, if the RPM indicator 115shows that the machine state is less than 600 RPM, the software mayperform an Eccentricity measurement to measure the amount of bent shaft.At above 600 RPM, the software turns off this measurement. In a thirdexample, a vertical hydro-turbine may have four different operatingstates that are indicated by discrete input values made available viathe DCS I/O bus 18. The software may set certain alarm levels or maymake certain measurement types available for output based on theparticular machine operating state.

In some preferred embodiments, firmware executed in the DCS logicgenerator card 16 monitors a first set of machinery health measurementscollected over a first range to determine a unique machine state (step314), and initiates a second set of unique machinery health measurementsover a second range based on the machine state indicated by the firstset of measurements (step 320). For example, the MHM module 10 mightnormally collect spectral vibration data only up to 2 kHz. However, if afirst set of measurements indicates that the High Frequency Detectionband is in an alarm condition, a second measurement with a spectrum of20 kHz may be initiated to allow determination of the cause of the alarmin the high frequency range.

API 670 Control Sheet Logic

The API 670 Standard, as defined by the American Petroleum Institute(API), provides detailed requirements for monitoring and protectingequipment used on critical rotating machinery in oil refinery andpetro-chemical plants. This standard covers the minimum requirements fora machinery protection system that may measure radial shaft vibration,casing vibration, shaft axial position, shaft rotational speed, pistonrod drop, phase reference, over-speed, surge detection, and criticalmachinery temperatures (such as bearing metal and motor windings).

Combining machine vibration monitoring with machine control typicallyrequires either (1) configuring a vibration machinery protection systemand then integrating the machinery protection system with a processcontrol system, or (2) inputting vibration information directly to theprocess control system and manually configuring the process controlsystem for best practices in vibration machinery protection, such asaccording to the API 670 Standard. There are several problems withoption (1), including that the integration process is time consuming,and requires training, additional hardware, software, configuration, andongoing support. The problem with option (2) is that process controlsystem operators are usually not skilled in the art of safelyconfiguring a process control system for the application task ofprotecting machines against high vibration.

Preferred embodiments described herein provide a system that addressesthe problems associated with option (2). The system includes UI softwarefor a process control system that guides a user and takes user inputbased on vibration industry best practices and the API 670 Standard. Thesystem uses built-in UI program logic to guide an unskilled user inbuilding an API 670 control sheet for a process control system.

In preferred embodiments, the user interface (UI) program logicpre-selects one second as the default time delay before a machinery tripoccurs as per the API 670 Standard, and automatically creates an AnalogInput block with this default time delay (step 322 in FIG. 14). As theterm is used herein, an Analog Input (AI) block is an object within thecontrol logic that is used to read in analog input signals from analoginput hardware. Typically, the AI block has internal alarm limits thatmay have configurable time delays before annunciating. By creating an AIblock with desired settings automatically, preferred embodiments of theinvention relieve the user from having to manually drag and drop the AIblock from a palette onto a workspace and open/configure it for alarmingwith time delay.

The UI program logic also presents user-selectable options for other API670 acceptable values of 2 second and 3 second delays, and automaticallycreates an AI block with the user-selected time delay (step 326). Insome embodiments, the UI program logic presents the user an option todeviate from the API 670 Standard by typing in a user-selected value fortime delay, and the software automatically creates an AI block with theuser-selected time delay. The user has the ability to accept the customvalue as an accepted deviation (step 324), which will be automaticallysaved to a list of deviations.

In some embodiments, the UI program logic automatically creates controlsheet logic to implement a machinery protection bypass per the API 670Standard for each sensor input. The UI program logic preferably providesthe user the option to enable or disable this bypass for each sensorinput (step 328). Also referred to herein as a Trip Bypass, a machineryprotection bypass allows for bypassing the machinery shutdown alarmlimits. Such a bypass would be needed, for example, if maintenance isbeing performed on the protection system, to avoid accidentally trippingthe machine.

The UI program logic also provides a means for the user to creategroupings for the sensors so that multiple sensors can be bypassed witha single user input. The UI program logic further provides a means forthe user to select a “force” that will force an output relay state tochange or to remain in a given state (step 332), and it automaticallycreates bypasses, groupings and forces in the control sheet (step 330).

In some embodiments, the UI program logic automatically creates acontrol sheet to implement a trip multiply per the API 670 Standard foreach sensor input. The UI program logic preferably provides the user anoption to select a default value, to enter an API 670 optional value, orto enter a user-preferred value that is outside of the API 670specification (step 334). The UI program logic also may provide the useran option to enable or disable the trip multiply for each sensor input.The UI program logic may further provide a means for the user to creategroupings for the sensors so that the trip multiply may be applied tomultiple sensors with a single user input, and it automatically createstrip multiplies and groupings in a control sheet (step 330).

In some embodiments, the UI program logic presents to the user an optionfor radial sensors to implement the API 670 Standard default that doesnot allow a failed sensor to contribute to a vote to trip. The user ispreferably presented an alternative option to allow a bad sensor,converter or cable to contribute to a vote to trip (step 336). In theseembodiments, the control sheet automatically votes in/out the sensor,converter and cable condition for trip decisions based on the user'sinput (step 330).

In some embodiments, the UI program logic presents to the user an optionto implement the API 670 Standard default condition that allows a failedthrust sensor to contribute to a vote to trip. The user is preferablypresented an alternative option to not allow a failed sensor, converteror cable to contribute to a vote to trip (step 336). In theseembodiments, the control sheet automatically votes in/out the sensor,converter and cable condition for trip decisions based on the user'sinput (step 330).

In some embodiments, the UI program logic presents to the user an optionto select latching or non-latching relays for each control system output(step 338). The UI program logic automatically creates a control sheetto latch or automatically reset the relay when the alarm condition istrue and then becomes false (step 330).

In some embodiments, the UI program logic provides a method for the userto enter alarm limits, alert limits and pre-alert limits for eachmeasurement channel or group of channels (step 340), and the UI programlogic automatically applies these limits to the control sheet fordetermining alarms and relay activation (step 330).

In some embodiments, the UI program logic creates a control sheet thatautomatically: (1) puts a date and time stamp on all incoming vibrationand status data; (2) configures a digital input (DI) for resettinglatching relays; (3) configures a digital output (DO) and a UI visibleelement for annunciating bypasses; and (4) configures a DO in thecontrol sheet to output the status of all hardware.

In some embodiments, sensor gap voltages and sensor bias voltages areinitially set up with default voltage values, and the UI program logicallows the user to edit these values (step 342) and they areautomatically updated in the control sheet (step 330).

In some embodiments, the UI program logic generates the control sheetaccording to the API 670 Standard to automatically capture and updatethe highest radial shaft vibration measurement at each bearing, allaxial measurements, the highest machine casing vibration measurement,the highest speed measurement, the highest rod drop measurement, and thehighest temperature measurement at each bearing.

In some embodiments, the UI program logic provides an option for theuser to select relay options (step 344) that the UI program logic usesto automatically configure the control sheet logic based on the userselection (step 330). These relay options preferably include normallyde-energized, normally energized, de-energized to alarm, and energizedto shutdown.

In some embodiments, the UI program logic provides options for the userto select the default ranges for axial thrust measurements (such as −40to +40 mils) and radial vibration measurements (0 to 125 microns), or toinput custom values for these ranges. User selections can be edited andsaved for future default configurations. For each selected range, the UIprogram logic generates the control sheet based on the default or customvalues. Custom values are preferably captured in an API 670 Standarddeviation report. In preferred embodiment, the UI program logicautomatically configures a circuit fault in the control sheet forvibration greater than 10 mils.

In some embodiments, when 2-out-of-3 logic is selected for axial thrustmeasurements, the UI program logic automatically configures the controlsheet by default to include a vote to trip on high vibration or sensorfailure.

In some embodiments, when a temperature sensor is used as input, the UIprogram logic automatically configures the control sheet by default to afull scale temperature range, such as 0 C to 150 C, and digital readoutsare automatically configured in the control logic with 1 degree ofresolution. Preferably, the UI program logic configures dual voting fortemperature as the default configuration as per the API 670 Standard.Other voting configurations that are accepted by the user will beflagged in the API 670 exceptions list.

In some embodiments, the UI program logic uses the configurationsettings for each configured channel to automatically generate graphicalelements that are displayed to the user on the DCS operator computer 60during runtime. These graphical elements preferably: (1) include bargraphs that are proportional to vibration, position, temperature, or anymain value; (2) provide graphical indication of alarm, alert andpre-alert levels; (3) include engineering units; (4) provide a graphicalindication of a highest value measured; (5) provide a name ordescription for each displayed value; (6) automatically configure tofull scale range; (7) provide an indication of sensor, cable, andconverter health; (8) provide a positive indication of fault or nofault; (9) provide an indication of the status of relays; (10) providean indication of circuit faults; (11) provide an indication of voteresults; (12) provide a method for launching a trend of historic valuesand live values; (13) provide a password protected method for the userto edit alarm limits; and (14) provide a method for the user to resetlatching relays.

In some embodiments, the user interface display screen includes a buttonthat the user can click that will reset the highest measured speed peak.Preferably, the control logic is automatically configured for thissoftware user input or DI that resets the speed peak.

In some embodiments, pre-configured HART devices automatically passalong their configuration data to the control logic, which automaticallyconfigures the control sheet accordingly.

Generally, machinery protection is a balancing act between safety andmachine availability. Some applications may lean more toward safety,such as tripping within 100 msec, or counting a failed sensor as a voteto trip. Other applications may lean more toward availability, such asimplementing a three second delay before trip, or not counting a failedsensor as a vote to trip. Accordingly, some embodiments of the UIprogram logic allow the user to “tune” multiple aspects of the controlsheet configuration more toward safety or more toward availability. Forexample, a single graphical slider may be displayed on the DCS operatorcomputer to provide an input to allow the user to select a point along asliding scale having maximum safety at one end and maximum availabilityat the other end. In this embodiment, the UI program logic automaticallyadjusts trip timing and voting logic based on the slider setting.

Some embodiments implement a method for automatically accessingconfiguration information for the MHM module 10 and accessingconfiguration information for the distributed control system 11, andcreating a control system configuration file used in configuring thedistributed control system to receive data from the MHM module 10 in thenative data format of the distributed control system. Some features ofsuch a method are described in U.S. Pat. Nos. 8,463,417 and 8,958,900,the entire contents of which are incorporated herein by reference.

The foregoing description of preferred embodiments for this inventionhave been presented for purposes of illustration and description. Theyare not intended to be exhaustive or to limit the invention to theprecise form disclosed. Obvious modifications or variations are possiblein light of the above teachings. The embodiments are chosen anddescribed in an effort to provide the best illustrations of theprinciples of the invention and its practical application, and tothereby enable one of ordinary skill in the art to utilize the inventionin various embodiments and with various modifications as are suited tothe particular use contemplated. All such modifications and variationsare within the scope of the invention as determined by the appendedclaims when interpreted in accordance with the breadth to which they arefairly, legally, and equitably entitled.

What is claimed is:
 1. A machinery health monitoring module thatprocesses machine vibration data based on vibration signals and providesthe machine vibration data to a distributed control system, themachinery health monitoring module comprising: signal conditioningcircuitry having an interface for receiving a plurality of analog sensorsignals from a plurality of sensors attached to a machine, amplificationand filter circuitry for conditioning the plurality of analog sensorsignals, and analog-to-digital conversion circuitry for converting theplurality of analog sensor signals into a plurality of digital sensorsignals; processing circuitry in electrical communication with thesignal conditioning circuitry, the processing circuitry comprising aplurality of parallel digital signal processing channels, each channeloperable to process a corresponding one of the plurality of digitalsensor signals in parallel with the processing of other of the pluralityof digital sensor signals in other of the channels, each channelconfigured to generate multiple different types of measurement data perchannel including scalar vibration values and vibration waveforms; andlogic generator circuitry in electrical communication with theprocessing circuitry and the signal conditioning circuitry, the logicgenerator circuitry operable to receive a first type of measurement datafrom the processing circuitry, and operable to determine that a machineoperating state has changed as indicated by the first type ofmeasurement data, and operable to configure the processing circuitry togenerate a second type of measurement data based on the change inmachine operating state, and operable to format the first type ofmeasurement data and the second type of measurement data according to aninput/output data protocol that is native to the distributed controlsystem.
 2. The machinery health monitoring module of claim 1 wherein theanalog sensor signals include at least one analog tachometer signal, andwherein: the analog-to-digital conversion circuitry is operable toconvert the at least one analog tachometer signal to a digitaltachometer signal; the processing circuitry is operable to process theat least one digital tachometer signal to generate machine speed data;and the logic generator circuitry is operable to determine that themachine operating state has changed as indicated by a change in themachine speed data.
 3. The machinery health monitoring module of claim 2wherein the logic generator circuitry is operable to determine that themachine operating state has changed from a steady-state speed conditionto a coast-down state based on the machine speed data, and is operableto configure the processing circuitry to generate the second type ofmeasurement data comprising a transient vibration waveform measuredwhile the machine is in the coast-down state.
 4. The machinery healthmonitoring module of claim 2 wherein the logic generator circuitry isoperable to determine that the machine operating state has changed basedon the machine speed data indicating a drop in machine speed from abovea predetermined speed threshold to below the predetermined speedthreshold, and is operable to configure the processing circuitry togenerate the second type of measurement data while the machine operatingstate is below the predetermined speed threshold and to generate thefirst type of measurement data while the machine operating state isabove the predetermined speed threshold.
 5. The machinery healthmonitoring module of claim 2 wherein the first type of measurement datais collected over a first frequency range and the second type ofmeasurement data is collected over a second frequency range that isdifferent from the first frequency range.
 6. The machinery healthmonitoring module of claim 2 wherein at least one of the paralleldigital signal processing channels of the processing circuitry isoperable to generate the measurement data in the form of a time waveformof the digital tachometer signal.
 7. The machinery health monitoringmodule of claim 1 wherein the logic generator circuitry is in electricalcommunication with an input/output bus of the distributed control systemthrough which the logic generator circuitry receives discrete inputvalues indicative of the machine operating state that are generated byother machine measurement modules connected to the input/output bus, andwherein the logic generator circuitry is operable to determine that themachine operating state has changed based on a change in one or more ofthe discrete input values, and wherein the logic generator circuitry isoperable to adjust alarm levels or generate the second type ofmeasurement data based on the change in one or more of the discreteinput values.
 8. The machinery health monitoring module of claim 1wherein the sensor signals include a machine vibration signal, andwherein the processing circuitry includes a peak value detection channeloperable to receive the machine vibration signal, sample the machinevibration signal during predetermined sample time periods, detect peakamplitude values of the machine vibration signal during the sample timeperiods, and produce a time series of the peak amplitude values, andwherein the first or second type of measurement data comprises the timeseries of the peak amplitude values.
 9. A distributed control systemcomprising: an input/output bus through which data are transferredaccording to a data communication protocol that is native to thedistributed control system; a machinery health monitoring module inelectrical communication with the input/output bus, the machinery healthmonitoring module comprising: signal conditioning circuitry having aninterface for receiving a plurality of analog vibration signals from aplurality of vibration sensors attached to a machine, amplification andfilter circuitry for conditioning the plurality of analog vibrationsignals, and analog-to-digital conversion circuitry for converting theplurality of analog vibration signals into a plurality of digitalvibration signals; processing circuitry in electrical communication withthe signal conditioning circuitry, the processing circuitry comprising aplurality of parallel digital processing channels, each channel forprocessing a corresponding one of the plurality of digital vibrationsignals to generate a plurality of scalar vibration values perprocessing channel; and logic generator circuitry in electricalcommunication with the processing circuitry, the logic generatorcircuitry executing instructions to automatically select one or more ofthe scalar vibration values from each of the processing channels basedon a measurement type selection, and format the one or more selectedscalar vibration values from each processing channel according to thedata communication protocol that is compatible with the input/outputbus; and a distributed control system controller in electricalcommunication with the input/output bus, the distributed control systemcontroller including interface circuitry having a plurality of fast-scanregisters, the interface circuitry operable to scan the input/output busat a predetermined rate to receive the one or more selected scalarvibration values into one or more of the plurality of fast-scanregisters.
 10. The distributed control system of claim 9 furthercomprising a distributed control system operator computer that generatesthe measurement type selection based on input from an operator.
 11. Adistributed control system comprising: an input/output bus through whichdata are transferred according to a data communication protocol that isnative to the distributed control system; a machinery health monitoringmodule in electrical communication with the input/output bus, themachinery health monitoring module comprising: signal conditioningcircuitry having an interface for receiving a plurality of analogvibration signals from a plurality of vibration sensors attached to amachine, amplification and filter circuitry for conditioning theplurality of analog vibration signals, and analog-to-digital conversioncircuitry for converting the plurality of analog vibration signals intoa plurality of digital vibration signals; processing circuitry inelectrical communication with the signal conditioning circuitry, theprocessing circuitry comprising a plurality of parallel digitalprocessing channels, each channel for processing a corresponding one ofthe plurality of digital vibration signals to generate multiple scalarvibration values per processing channel; and logic generator circuitryin electrical communication with the processing circuitry, the logicgenerator circuitry operable to receive the multiple scalar vibrationvalues and format the multiple scalar vibration values according to aninput/output communication protocol that is native to the distributedcontrol system; and a distributed control system controller comprising:interface circuitry that scans the input/output bus at a predeterminedrate to receive one or more of the scalar vibration values therefrom;and logic circuitry for executing a control logic routine that generatescontrol signals based on logical processing of one or more of the scalarvibration values, the control logic routine initially configured toimplement a default trip time delay as prescribed by an industrystandard, wherein the control logic routine is automaticallyreconfigured to implement a selected trip time delay other than thedefault trip time delay based on a trip time delay selection; and adistributed control system operator computer in electrical communicationwith the distributed control system controller, the distributed controlsystem operator computer generating configuration data for automaticallyreconfiguring the control logic routine to implement the selected triptime delay based at least in part on the trip time delay selection. 12.The distributed control system of claim 10 wherein the distributedcontrol system operator computer is operable to generate configurationdata for configuring the machinery health monitoring module based on themeasurement type selection.
 13. The distributed control system of claim9 wherein: the logic generator circuitry executes instructions toautomatically select two of the scalar vibration values from at leastone of the processing channels based on the measurement type selection,and format the two selected scalar vibration values according to thedata communication protocol that is compatible with the input/outputbus; and the interface circuitry of the distributed control systemcontroller scans the input/output bus at a predetermined rate to receivethe two selected scalar vibration values into two of the fast-scanregisters.
 14. The distributed control system of claim 11 wherein thecontrol logic routine is initially configured to implement a machineryprotection bypass as prescribed by the industry standard for a pluralityof sensor inputs corresponding to the plurality of sensors, and isautomatically reconfigured to disable the machinery protection bypassfor one or more of the sensor inputs based on a machinery protectionbypass selection.
 15. The distributed control system of claim 11 whereinthe control logic routine is initially configured to implement a tripmultiply as prescribed by the industry standard for all sensor inputscorresponding to the plurality of sensors, and is automaticallyreconfigured to disable the trip multiply for one or more of the sensorinputs based on a trip multiply selection.
 16. The distributed controlsystem of claim 11 wherein the control logic routine is initiallyconfigured to implement voting logic that allows a failed sensor tocontribute to a vote to trip as prescribed by the industry standard, andis automatically reconfigured to disallow a failed sensor to contributeto a vote to trip based on a failed sensor voting option selection. 17.The distributed control system of claim 11 wherein the control logicroutine is initially configured to implement alarm limits or alertlimits as prescribed by the industry standard, and is automaticallyreconfigured based on alarm limit selections or alert limit selections.18. The distributed control system of claim 11 wherein the distributedcontrol system operator computer executes instructions for generatingthe configuration data in the form of an analog input block comprisingan object within the control logic routine that is used in reading theanalog vibration signals from the signal conditioning circuitry.